EP0990630B1 - Structural body comprising aluminum nitride and method of producing the same - Google Patents

Structural body comprising aluminum nitride and method of producing the same Download PDF

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Publication number
EP0990630B1
EP0990630B1 EP99307612A EP99307612A EP0990630B1 EP 0990630 B1 EP0990630 B1 EP 0990630B1 EP 99307612 A EP99307612 A EP 99307612A EP 99307612 A EP99307612 A EP 99307612A EP 0990630 B1 EP0990630 B1 EP 0990630B1
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EP
European Patent Office
Prior art keywords
silicon carbide
sintered body
carbide film
silicon
aluminum nitride
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EP99307612A
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German (de)
English (en)
French (fr)
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EP0990630A1 (en
Inventor
Masao Nishioka
Naotaka Kato
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NGK Insulators Ltd
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NGK Insulators Ltd
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/67—Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
    • H01L21/67005—Apparatus not specifically provided for elsewhere
    • H01L21/67011—Apparatus for manufacture or treatment
    • H01L21/67098—Apparatus for thermal treatment
    • H01L21/67103—Apparatus for thermal treatment mainly by conduction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/85—Coating or impregnation with inorganic materials
    • C04B41/87—Ceramics
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
    • C04B41/81—Coating or impregnation
    • C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/10—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor
    • H05B3/16—Heating elements characterised by the composition or nature of the materials or by the arrangement of the conductor the conductor being mounted on an insulating base
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/263—Coating layer not in excess of 5 mils thick or equivalent
    • Y10T428/264—Up to 3 mils
    • Y10T428/265—1 mil or less

Definitions

  • the present invention relates to a structural body and a method of producing the same having an excellent heat cycle resistivity.
  • an electrostatic chuck is used for chucking a semiconductor wafer and retaining it in the steps of film forming such as transfer, exposure, thermal CVD (Chemical Vapor Deposition method), plasma CVD, and sputtering of the semiconductor wafer, fine working, washing, etching, dicing and so on.
  • film forming such as transfer, exposure, thermal CVD (Chemical Vapor Deposition method), plasma CVD, and sputtering of the semiconductor wafer, fine working, washing, etching, dicing and so on.
  • thermal CVD Chemical Vapor Deposition method
  • plasma CVD plasma chemical vapor deposition method
  • sputtering of the semiconductor wafer fine working, washing, etching, dicing and so on.
  • dense ceramics having a high density are used recently.
  • halogen corrosive gasses such as CIF 3 and so on are widely used as etching gas and cleaning gas.
  • the substrate of the electrostatic chuck has a high heat conductivity. Further, it is desired that the substrate of the electrostatic chuck has a thermal shock resistivity so as to be fractured due to a rapid temperature variation.
  • Dense aluminum nitride has a high corrosive resistivity with respect to the halogen corrosive gas as mentioned above.
  • the dense aluminum nitride is known as a material having a high heat conductivity such as a volume resistivity of greater than 10 8 ohm-cm.
  • the dense aluminum nitride is known as a substance having a high thermal shock resistivity. Therefore, it is thought to be preferred that the substrate of the electrostatic chuck or the heater used for producing semiconductors is formed by an aluminum nitride sintered body.
  • the inventors studied a corrosion resistive member in which a silicon carbide film was formed on a surface of the aluminum nitride substrate by means of chemical vapor deposition method as in JP II 060356A.
  • a corrosion resistive member was subjected to a heat cycle was applied to the corrosion resistive member.
  • An object of the present invention is to provide a structural body in which a silicon carbide film is formed on an aluminum nitride sintered body, which does not generate cracks or abruptions of the silicon carbide film when a heat cycle is applied to the structural body.
  • a structural body comprises an aluminum nitride sintered body, a silicon carbide film formed on a surface of said aluminum nitride sintered body, and an intermediate layer generated between said aluminum nitride sintered body and said silicon carbide film, said intermediate layer being mainly made of silicon nitride.
  • a method of producing the structural body mentioned above comprises the steps of flowing hydrogen at a film forming temperature; flowing a gas for a first silicon generation compound including at least silicon, chlorine and hydrogen; and flowing a gas for a second silicon generation compound and a carbon generation compound; thereby forming said silicon carbide film to said aluminum nitride sintered body by means of a chemical vapor deposition method.
  • the inventors performed a number of screenings in such a manner that various chemical vapor deposition methods were examined, and in such a manner that a microstructure and a heat cycle test of a corrosion resistive member, in which a silicon carbide film was formed on an aluminum nitride sintered body actually, were also examined in detail.
  • the inventors found that, if the silicon carbide film was generated under a particular condition mentioned below, an intermediate layer made of mainly silicon nitride was sometimes generated on a boundary between the sintered body and the silicon carbide film, and in this case, a heat cycle resistivity was extraordinarily improved.
  • the present invention was achieved by these findings.
  • a main ingredient of the intermediate layer is silicon nitride, and it is preferred that an amount of silicon nitride is greater than 90 wt%.
  • aluminum originated from aluminum nitride sintered body and carbon originated from silicon carbide may be included.
  • an amount of aluminum is smaller than 5 wt% and an amount of carbon is smaller than 5 wt%.
  • chlorine is included sometimes as impurities, but it is preferred that an amount of chlorine is smaller than 1 wt%.
  • a thermal stress occurs due to a difference of thermal expansion coefficient between the sintered body and the silicon carbide film. Since a thermal expansion coefficient of the silicon carbide film is smaller than that of the sintered body, a compression stress is generated in the silicon carbide film and a tensile stress is generated in the sintered body. If the silicon carbide film is arranged on the sintered body only in a physical manner without being connected, the silicon carbide film is peeled off from the sintered body due to these stresses. However, if the intermediate layer according to the invention is generated, the intermediate layer has a chemical bonding force and thus it is likely to be firmly connected to both of the sintered body and the silicon carbide film.
  • a thickness of the intermediate layer In order to prevent an abruption of the silicon carbide film, it is preferred to set a thickness of the intermediate layer to larger than 0.2 ⁇ m more preferably larger than 2 ⁇ m. Moreover, an upper limitation of a thickness of the intermediate layer is not generally set. However, it is difficult to make a thickness of the intermediate layer greater than a predetermined value due to an actual producing process. From this view point, it is preferred to set a thickness of the intermediate layer to smaller than 20 ⁇ m and more preferably to smaller than 10 ⁇ m from the view point of heat cycle resistivity.
  • a method of producing the intermediate layer is not limited, but it is preferred to use the following methods. That is to say, a method of producing the structural body, comprises the steps of, when a silicon carbide film is formed to the aluminum nitride sintered body by means of a chemical vapor deposition method; flowing hydrogen at a film forming temperature; flowing a gas for a first silicon generation compound including at least silicon, chlorine and hydrogen; and flowing a gas for a second silicon generation compound and a carbon generation compound.
  • the first silicon generation compound it is preferred to use at least one compound selected from the group of SiCl 4 , SiHCl 3 , and SiH 2 Cl 2 .
  • the second silicon generation compound it is preferred to use at least one compound selected from the group of SiCl 4 , SiHCl 3 , SiH 2 Cl 2 and SiH 4 .
  • the carbon generation compound it is especially preferred to use at least one compound selected from the group of CH 4 , C 2 H 6 and C 3 H 8 . It is preferred that the first silicon generation compound is the same as the second silicon generation compound, but they may be different with each other.
  • a gas for the first silicon generation compound including at least hydrogen is introduced prior to a gas for the carbon generation compound at a high temperature. Therefore, a silicon chloride is acted with hydrogen and resolved to generate hydrogen chloride.
  • the thus generated hydrogen chloride gas functions to corrode and activate a surface of the aluminum nitride.
  • silicon atoms are bonded to generate silicon nitride, carbon introduced after that become further reactable with silicon, and the thus generated silicon carbide is likely to be firmly connected to silicon nitride as a substrate.
  • An introducing period of the first silicon generation compound including chlorine such as silicon tetrachloride is determined suitably according to a film generation temperature so as to generate the intermediate layer having a desired thickness. It is preferred that the film generation temperature is set to 1350-1500°C more preferably 1400-1450°C.
  • Heat cycle resistivity of the sintered body and the silicon carbide film was further improved, by making a purity of aluminum nitride of the aluminum sintered body to greater than 90 % more preferably greater than 94 %. This is because the effects of oxides in the sintered body can be reduced. Moreover, a relative density of the sintered body is preferably set to greater than 94% from the view points of strength and heat conductivity.
  • the structural body according to the invention shows an extraordinarily high corrosion resistivity with respect to chloride gas. Particularly, in a high temperature region of 600-1000°C, it is preferred to use the structural body according to the invention as a corrosion resistive member exposed especially to chloride gas.
  • the structural body according to the invention can be applied to various kinds of products.
  • the structural body according to the invention can be preferably applied to an electromagnetic radiation transmission member.
  • electromagnetic radiation transmission window high frequency electrode apparatus, tube for generating high frequency plasma, dome for generating high frequency plasma.
  • the structural body according to the invention can be applied to a suscepter for setting a semiconductor wafer.
  • a suscepter there are ceramic electrostatic chuck, ceramics heater, high frequency electrode apparatus.
  • the structural body according to the invention can be used for a substrate of the semiconductor producing apparatus such as shower plate, lift pin used for supporting semiconductor wafer, shadow ring, and dummy wafer.
  • the structural body according to the invention is applied to the member which is set in plasma, there is an advantage such that a charge-up level of a surface of the structural body in plasma can be reduced by means of the silicon carbide film.
  • the structural body according to the invention is applied to the suscepter set in plasma, it is possible to reduce charge generation on a surface of the suscepter since the surface of the suscepter is covered with the silicon carbide film having a semi-conductive property.
  • the structural body according to the invention can be applied to the electrostatic chuck.
  • the electrostatic chuck was produced by embedding a metal electrode in the substrate made of an aluminum nitride sintered body.
  • it is necessary to protect the metal electrode from corrosive atmospheres it is necessary to increase a total thickness of the substrate. Therefore, there is a tendency such that a heat capacity of the electrostatic chuck becomes larger. If the heat capacity becomes larger, it takes an additional time for heating and cooling operations.
  • the electrostatic chuck can be obtained by forming the silicon carbide film on one surface of aluminum nitride sintered body according to the invention, wherein the silicon carbide film is used as the electrostatic chuck electrode and the sintered body is used as a dielectric layer.
  • the silicon carbide film has a high durability with respect to corrosive atmospheres and is easy to make a thickness of the sintered body thinner as compared with the metal electrode.
  • the silicon carbide film has no problem as compared with the metal embedded electrode. Therefore, it is possible to make a total heat capacity of the electrostatic chuck smaller.
  • a silicon carbide film was formed on an aluminum nitride sintered body by using a chemical vapor deposition (CVD) apparatus shown schematically in Fig. 1.
  • a substrate 1 was set in a furnace.
  • the substrate 1 was supported by a supporting member 5.
  • a raw material supply tube 8 having a front shape of character T was set.
  • the raw material supply tube 8 comprises a base portion 8b and a blowing portion 8a extended breadthwise.
  • a predetermined number of gas discharge outlets 9 were arranged at a surface 8c opposed to a substrate of the blowing portion 8a.
  • a numeral 6 was an inner cylindrical member and a numeral 7 was an external heater.
  • a spacing between the surface 8c of the raw material supply tube 8 and the substrate 1 was set to 100 mm-300 mm.
  • a gas was fed from the gas discharge outlets 9 while the raw material supply tube 8 was rotated.
  • a raw material gas for CVD was fed from the gas discharge outlets 9, flowed in a space 10, encountered to a surface of the substrate 1, flowed along a surface of the substrate 1, and was fed through gas discharge holes 3 formed in the supporting member 5.
  • a structural body was produced according to the method mentioned above by using the apparatus shown in Fig. 1.
  • argon was only flowed in the furnace during a temperature ascending operation up to 1425°C, and hydrogen, silicon tetrachloride, methane were flowed at 1425°C.
  • examples 1, 2, 3 according to the invention argon was only flowed in the furnace during a temperature ascending operation up to respective film forming temperatures, hydrogen was only flowed for 10 minutes at respective film forming temperatures after that, then hydrogen and silicon tetrachloride were flowed for 1 minute, and then methane was flowed in addition.
  • a heat cycle test at a temperature range between room temperature and 900°C was performed.
  • Sample pieces each having a rectangular shape of 4 mm ⁇ 3 mm ⁇ 50 mm were cut out from respective structural bodies.
  • the silicon carbide film was arranged on a plane defined by 4 mm ⁇ 50 mm.
  • the thus prepared sample piece 14 was supported by a chuck member 15 made of Inconel in a space 19 maintained at room temperature.
  • a portion between a resistance heating furnace 11 and a cylinder 17 was covered with a closed vessel 16, and an argon gas under atmosphere pressure was flowed in the closed vessel 16.
  • An outer wall of the resistance heating furnace 11 was covered with a metal plate in a highly hermetic manner.
  • the sample piece 14 was inserted into a furnace inner space 13 of the resistance heating furnace 11 by driving the air pressure cylinder 17.
  • a numeral 12 was a resistance heater.
  • a temperature of the furnace inner space 13 was maintained at 900°C.
  • the sample piece 14 was maintained for 1 minute in the furnace inner space 13, and then it was pulled out from the furnace inner space 13 by driving the air pressure cylinder 17.
  • An argon gas was blown from a nozzle 18 having a diameter of 2 mm at a rate of 2 litter/minute and the sample piece 14 was cooled down for 1 minute.
  • a temperature of the sample piece 14 when it was completely pulled out from the furnace inner space 13 was lower than 30°C.
  • An argon gas blown from the nozzle 18 was discharged into an atmosphere through a check valve arranged to the closed vessel 16.
  • Table 1 raw material gas introducing method unit litre/minute results of heat cycle test 10 100 1000 10000 50000 comparative example 1 temperature ascending time predetermined time 0/5 - - - - film forming temperature 1425°C Ar 7.5 7.5 H 2 17.5 SiCl 4 5.2 CH 4 4 example 1 temperature ascending time 10 min. 1 min.
  • a composition of the intermediate layer was 60 wt% of silicon, 35 wt% of nitrogen, 1 wt% of carbon, 2 wt% of aluminum and 0.04 wt% of chlorine. Moreover, the intermediate layer was measured by using micro-focus X-ray. As a result, it was confirmed that there was a silicon nitride crystal corresponding to JCPDS card No. 33-1160 in the intermediate layer.
  • Fig. 6 shows an observation result of the specimen according to the example 2.
  • the intermediate layer having a thickness of 0.2 ⁇ m was generated.
  • Fig. 7 shows an observation result of the specimen according to the comparative example 1. No intermediate layer was generated, and the silicon carbide film was peeled off from the aluminum nitride sintered body.
  • a composition of the intermediate layer of the example 4 was silicon nitride as a main ingredient, 3 wt% of aluminum and 4 wt% of carbon, that of the example 5 was silicon nitride as a main ingredient, 4 wt% of aluminum and 3 wt% of carbon, and that of the example 6 was silicon nitride as a main ingredient, 2 wt% of aluminum and 2 wt% of carbon.
  • Table 2 raw material gas introducing method unit litre/minute results of heat cycle test 10 100 1000 10000 50000 comparative example 2 temperature ascending time predetermined time 0/5 - - - - film forming temperature 1425°C Ar 7.5 7.5 H 2 17.5 SiCl 4 5.2 C 3 H 8 1.3 example 4 temperature ascending time 10 min 1 min predetermined time 5/5 5/5 5/5 5/5 film forming temperature 1425°C Ar 7.5 7.5 7.5 H 2 17.5 17.5 17.5 SiCl 4 5.2 5.2 C 3 H 8 1.3 example 5 temperature ascending time 10 min. 1 min.
  • predetermined time 5/5 5/5 2/5 1/5 0/5 film forming temperature 1400°C Ar 7.5 7.5 17.5 7.5 7.5 H 2 17.5 17.5 SiCl 4 5.2 5.2 C 3 H 8 1.3 example 6 temperature ascending time 10 min. 1 min. predetermined time 5/5 5/5 5/5 5/5 film forming temperature 1450°C Ar 7.5 7.5 7.5 7.5 H 2 17.5 17.5 17.5 SiCl 4 5.2 5.2 C 3 H 8 1.3
  • a composition of the intermediate layer of the example 7 was silicon nitride as a main ingredient, 2 wt% of aluminum and 3 wt% of carbon
  • that of the example 8 was silicon nitride as a main ingredient, 1.5 wt% of aluminum and 3 wt% of carbon
  • that of the example 9 was silicon nitride as a main ingredient, 2 wt% of aluminum and 2 wt% of carbon.
  • Table 3 raw material gas introducing method unit litre/minute results of heat cycle test 10 100 1000 10000 50000 comparative example 3 temperature ascending time predetermined time 0/5 - - - - film forming temperature 1425°C Ar 7.5 7.5 H 2 17.5 SiHCl 3 5.2 CH 4 4 example 7 temperature ascending time 10 min. 1 min. predetermined time 5/5 5/5 5/5 5/5 5/5 film forming temperature 1425°C Ar 7.5 7.5 7.5 7.5 H 2 17.5 17.5 17.5 SiHCl 3 5.2 5.2 CH 4 4 example 8 temperature ascending time 10 min. 1 min.
  • predetermined time 5/5 5/5 3/5 2/5 0/5 film forming temperature 1400°C Ar 7.5 7.5 7.5 7.5 H 2 17.5 17.5 17.5 SiHCl 3 5.2 5.2 CH 4 4 example 9 temperature ascending time 10 min. 1 min. predetermined time 5/5 5/5 5/5 5/5 film forming temperature 1450°C Ar 7.5 7.5 7.5 7.5 H 2 17.5 17.5 17.5 SiHCl 3 5.2 5.2 CH 4 4
  • compositions of the intermediate layers according to respective specimens shown in Table 3 were silicon nitride as a main ingredient, 1-3 wt% of aluminum, 1-3 wt% of carbon and 0.02-0.3 wt% of chlorine. From these results, it was confirmed that a thickness of the intermediate layer was preferable if it was greater than 0.2 ⁇ m, more preferable if it was greater than 2 ⁇ m and further more preferable if it was greater than 4 ⁇ m.
  • a purity of aluminum nitride in the sintered body was varied as shown in Table 5.
  • Compositions other than aluminum nitride in the sintered body were sintering agents mainly composed of yttrium, ytterbium, oxygen, magnesium, carbon and so on and inevitable impurities.
  • a purity of aluminum nitride was preferable if it was greater than 90 % and more preferable if it was greater than 94 %.
  • specimens were prepared.
  • this experiment 6 use was made of a discoid substrate having a thickness of 2 mm and a diameter of 200 mm, which was made of the aluminum nitride sintered body having a purity of 99.5 %.
  • the silicon carbide film having a thickness of 50 ⁇ m was formed according to the condition of the example 1 in the experiment 1.
  • a thickness of the intermediate layer was 8 ⁇ m.
  • Compositions other than silicon nitride in the intermediate layer were 2 wt% of aluminum, 1 wt% of carbon and 0.05 wt% of chlorine.
  • the thus prepared specimen was exposed in chlorine plasma at 825°C.
  • a flow amount of chlorine gas was 300SCCM
  • a pressure was 13.3Pa (0.1 Torr)
  • an alternate current power was 800 watt
  • an exposed time was 2 hours.
  • the silicon carbon film was not corroded at all.
  • the heater in which the silicon carbide film itself is used as a resistance heating element, will be explained.
  • a metal resistance heating element is embedded in a substrate made of an aluminum nitride sintered body, it is necessary to arrange portions of the resistance heating element with a spacing so as to prevent a contact between these portions in the substrate. Therefore, when the heater is viewed from a heating surface side, a temperature of the heating surface positioned just on the resistance heating element becomes high, but a temperature of the heating surface positioned on a portion in which the resistance heating element is not embedded becomes low, so that a temperature variation on the heating surface is generated. Moreover, since a heat capacity of the heater becomes larger, it is difficult to perform abrupt heating and cooling operations, and thus a precise temperature control cannot be performed.
  • the resistance heating element is formed by patterning the silicon carbide film
  • the heater in which the metal resistance heating element is embedded in the sintered body since there is no limitations as that of the heater in which the metal resistance heating element is embedded in the sintered body, it is possible to eliminate the temperature variation on the heating surface mentioned above by making a spacing of the pattern of the silicon carbide film sufficiently smaller. Moreover, in this case, it is possible to perform the abrupt heating and cooling operations.
  • a pattern made of a metal film is formed on a surface of the sintered body and the pattern generates heat
  • the metal film is gradually peeled off due to a difference of thermal expansion coefficient between the metal film and the sintered body when a heat cycle is applied, or, such that a resistance value is varied partially due to an oxidation of the metal film.
  • the silicon carbide film pattern according to the invention is used as the resistance heating element, the resistance heating element is not varied on a surface of the substance even after applying a long term heat cycle.
  • Fig. 8 is a plan view of a heater
  • Fig. 9 is a perspective view of the heater 21
  • Fig. 10 is a partially cross sectional view of the heater 21.
  • a plate-like substrate 22 having a dimension of 300 mm ⁇ 300 mm ⁇ 3 mm and made of an aluminum nitride sintered body having a purity of 99.5 % was prepared.
  • a silicon carbide film having a thickness of about 100 ⁇ m was formed on one surface of the substrate 22 according to the method shown in the experiment 1.
  • An intermediate layer having a thickness of 7 ⁇ m was generated at a boundary between the silicon carbide film and the substrate.
  • a main ingredient of the intermediate layer was silicon nitride, and, 2 wt% of aluminum, 1 wt% of carbon, 0.05 wt% of chlorine were included therein.
  • recesses 24 each having a depth of about 200 ⁇ m and a width of 1 mm were formed by using a diamond cutter and a resistance heating element pattern 23 was formed.
  • the pattern 23 comprised linear portions 23c and connection portions 23d for connecting ends of respective linear portions 23c.
  • a width of the linear portion 23c was 1 mm.
  • Aluminum nitride was exposed at a bottom of the recess 24.
  • Platinum wires 26 were connected to both ends 23a and 23b of the pattern 23 respectively and a power was supplied to the resistance heating element pattern 23 through the platinum wires 26 so as to generate heat. After a power supply was started, a temperature of a surface of the substrate 22 to which no pattern 23 was formed was measured by using a radiation.
  • a temperature difference in a region positioned within 8 mm from respective corner portions of the substrate was within 0.4°C, and a temperature was increased uniformly in this region.
  • a resolution of the radiation thermometer was 0.5 mm, a substantial temperature distribution was not detected on the heater surface.
  • the thus prepared heater was subjected to a heat cycle test in argon atmosphere including 5 % of hydrogen.
  • One heat cycle was as follows: the temperature of the heater was raised to 500°C for 0.5 hour, maintained at 500°C for 0.1 hour and lowered to room temperature for 0.5 hour. After 100 heat cycles, a temperature distribution was measured on the heater surface by using the radiation thermometer. As a result, an average temperature difference was within ⁇ 0.2°C and a temperature distribution was within ⁇ 0.4°C, as compared with the heater before the heat cycle test.
  • a heater in which a metal resistance heating element was embedded in an aluminum nitride sintered body was known.
  • a heater was not known which was used preferably under a condition such that a heat cycle between room temperature and a high temperature region such as 600-1100°C was applied and it was exposed in a corrosive gas especially chlorine corrosive gas.
  • a corrosive gas especially chlorine corrosive gas.
  • a heater which solved all the disadvantages mentioned above could be achieved by embedding a resistance heating element in an aluminum nitride sintered body, covering overall surface of the sintered body, and forming an intermediate layer at a boundary between the sintered body and the silicon carbon film.
  • the silicon carbide film formed by a chemical vapor deposition method has an extraordinarily high corrosion resistivity with respect to a chlorine corrosive gas in a high temperature region especially in a high temperature region of 600-1100°C.
  • the silicon carbide film is integrated with the aluminum nitride sintered body, in which a resistance heating element is embedded, through the intermediate layer, the structural body having a strong heat cycle resistivity can be achieved. This reason is assumed as follows.
  • the structural body according to the invention is used as a suscepter and a heat from an external heat source (for example infrared lamp) is applied to the suscepter, a heat from the external heat source is first introduced to the silicon carbide film by means of a heat radiation, and then conducted to the aluminum nitride sintered body through the intermediate layer.
  • an external heat source for example infrared lamp
  • a thermal expansion coefficient of the silicon carbide film is greater than that of the aluminum nitride sintered body, if both of the silicon carbide film and the aluminum nitride sintered body are heated, the silicon carbide film is expanded largely as compared with the aluminum nitride sintered body and thus a compression stress is applied to the silicon carbide film.
  • a temperature of the silicon carbide film is first increased rapidly due to a heat radiation for the silicon carbide film, an excess compression stress is liable to be applied to the silicon carbide film. Therefore, even if taking into consideration of a buffer function of the intermediate layer according to the invention, abruptions of the film are liable to be generated after the heat cycle is applied.
  • the silicon carbide film is integrated through the intermediate layer, with the aluminum nitride sintered body, in which the resistance heating element is embedded, a heat from the resistance heating element is conducted through the sintered body by means of a heat conduction and reaches to the silicon carbide film through the intermediate layer.
  • a heat capacity of the sintered body is greater than that of the silicon carbide film and the silicon carbide film is thin, when a heat is conducted from the sintered body to the silicon carbide film through the intermediate layer during a temperature ascending step, a temperature difference between the silicon carbide film and an outermost region of the sintered body is small, and a temperature of the silicon carbide film is lower than that of the sintered body.
  • resistance heating element which is embedded in the aluminum nitride sintered body
  • metal wire having a coil spring shape, metal foil and metal plate are preferably used, and they are known in a heater filed.
  • a heater in which the resistance heating element is embedded in the aluminum nitride sintered body, at least a part of the resistance heating element is made of a conductive net-like member and an aluminum nitride is filled in a net of the net-like member.
  • the heater having the construction mentioned above shows an extraordinary durability with respect to a heat cycle especially between a high temperature region on a low temperature region such as a room temperature region.
  • Materials of the net-like member are not limited, but it is preferred to use a metal having a high melting point when a temperature becomes greater than 600°C during use.
  • a metal having a high melting point use is made of tungsten, molybdenum, platinum, rhenium, hafnium and an alloy thereof.
  • the net-like member As a configuration of the net-like member, it is preferred to use the net-like member formed by fibers or wires. In this case, if a cross section of the fiber or the wire is circular, it is possible to reduce a stress concentration due to thermal expansion.
  • the net-like member should be cut into a slender string like a picture drawn with a single stroke of the brush.
  • a current is flowed toward a longitudinal direction of the net-like member formed by the slender strips, an unevenness of temperature distribution due to a current concentration is not liable to be generated as compared with the circular net-like member.
  • Fig. 11a is a plan view showing a ceramics heater 31 according to another embodiment of the invention and Fig. 11b is a cross sectional view cut along Xb-Xb line in Fig. 11a.
  • a net-like member 34 is embedded in a substrate 32 having for example discoid shape.
  • a terminal 33A which continues to a rear surface 32b is embedded, and at a peripheral portion of the substrate 32, a terminal 33B which continues to the rear surface 32b is embedded.
  • the terminal 33A and the terminal 33B are connected through the net-like member 34.
  • a numeral 32a is a heating surface.
  • the substrate 32 comprises an aluminum nitride sintered body 36 having a discoid shape and a silicon carbide film 35 which covers a surface of the sintered body 36.
  • the net-like member 34 is formed by a net having a configuration shown in for example Figs. 12a-12c. It should be noted that a fine net configuration of the net-like member 34 is not shown in Figs. 11a and 11b due to a size limitation.
  • the net-like member 34 has a convoluted shape in a major plane between the terminals 33A and 33B.
  • the terminals 33A and 33B are connected to a power supply cable not shown.
  • Figs. 12a-12c are cross sectional views respectively showing one embodiment of the net-like member.
  • a net-like member 46 shown in Fig. 12a longitudinal wires 46b and transversal wires 46a are knitted in a three-dimensional manner, and both of the longitudinal wires and the transversal wires waves.
  • transversal wires 47a are straight and longitudinal wires 47b are bent.
  • a net-like member 48 shown in Fig. 12c longitudinal wires 48b and transversal wires 48a are knitted in a three-dimensional manner, and both of the longitudinal wires and the transversal wires waves.
  • the net-like member 48 is worked by a rolling mill, and thus outer surfaces of the longitudinal wires and transversal wires are aligned along one-dotted chain lines A and B.
  • Aluminum nitride powders obtained by a reduction nitriding method were used as raw material powders.
  • contents of Si, Fe, Ca, Mg, K, Na, Cr, Mn, Ni, Cu, Zn, W, B, Y were respectively smaller than 100 ppm, and the other metal components except for aluminum were not detected.
  • a preliminarily formed body having a discoid shape was produced by forming the raw material powders by applying one directional stress thereto.
  • a resistance heating element made of molybdenum having a coil spring shape was embedded in the preliminarily formed body.
  • the preliminarily formed body was sintered by a hot press method under a pressure of 200 kgf/cm 2 at 1900°C to obtain an aluminum nitride sintered body.
  • the sintered body had a diameter of 250 mm and a thickness of 20 mm.
  • a silicon carbide film having a thickness of 50 ⁇ m was formed on a surface of the sintered body according to the condition of the example 1 in the experiment 1.
  • a thickness of the intermediate layer was 7 ⁇ m.
  • a chemical composition other than silicon nitride in the intermediate layer was 2 wt% of aluminum, 1 wt% of carbon and 0.04 wt% of chlorine.
  • a silicon wafer was set on the heater according to this embodiment.
  • a heater 1 in which no silicon carbide film was formed in the sintered body was produced.
  • a heater 2 in which the silicon carbide film having a thickness of 50 ⁇ m was formed according to the condition of the comparative example 1 in the experiment 1, was produced.
  • Respective heaters were exposed in a chlorine plasma.
  • a flow amount of a chlorine gas was 300SCCM
  • a pressure was 13 ⁇ 3 Pa (0.1 Torr)
  • an alternating current power was 800 W
  • an exposing time was 2 hours.
  • Power was supplied to the resistance heating element of the heater and a temperature of the silicon wafer was maintained at 800°C.
  • the silicon carbide film was not corroded at all in the example according to the invention 1.
  • the substrate was corroded heavily in the comparative example.
  • a contamination level of A1 with respect to the silicon wafer was as follows. In the heater according to the comparative example 1, a contamination level was 10 15 atm/cm 2 .
  • a contamination level was 10 10 atm/cm 2 . Since the contamination level of 10 10 atm/cm 2 was the same as that of the silicon wafer before processing, a plasma heating process could be performed under a condition of substantially no silicon wafer contamination in the heater according to the invention.
  • the silicon carbide film has a conductive property, it was possible to prevent a particle adhesion due to an electrostatic potential which was a problem in the aluminum nitride sintered body having an insulation property. Especially, it was possible to prevent a generation of electrostatic potential completely by connecting the silicon carbide film to the ground.
  • the heat cycle test was performed as is the same as the experiment 1.
  • the silicon carbide film was not peeled off even after 10000 heat cycles.
  • the silicon carbide film was peeled off after 20 heat cycles.
  • the silicon carbide film is formed on a surface of the aluminum nitride sintered body, the silicon carbide film is firmly connected to the sintered body, it is possible to prevent abruption of the silicon carbide film when the heat cycle is applied to the structural body.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • General Physics & Mathematics (AREA)
  • Manufacturing & Machinery (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Vapour Deposition (AREA)
  • Resistance Heating (AREA)
  • Ceramic Products (AREA)
EP99307612A 1998-09-29 1999-09-28 Structural body comprising aluminum nitride and method of producing the same Expired - Lifetime EP0990630B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP29010598 1998-09-29
JP29010598 1998-09-29

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EP0990630B1 true EP0990630B1 (en) 2007-11-14

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EP (1) EP0990630B1 (ko)
KR (1) KR100381588B1 (ko)
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TW477782B (en) * 1998-09-29 2002-03-01 Ngk Insulators Ltd Structural body and method of producing the same
US6797628B2 (en) * 2002-01-16 2004-09-28 Micron Technology, Inc. Methods of forming integrated circuitry, semiconductor processing methods, and processing method of forming MRAM circuitry
JP2006044980A (ja) * 2004-08-04 2006-02-16 Sumitomo Electric Ind Ltd 窒化アルミニウム焼結体
TWI249470B (en) * 2005-03-09 2006-02-21 Univ Nat Central Structure and method of thermal stress compensation
US10325800B2 (en) * 2014-08-26 2019-06-18 Applied Materials, Inc. High temperature electrostatic chucking with dielectric constant engineered in-situ charge trap materials
CN111087229B (zh) * 2019-12-05 2022-03-08 宜兴市耐火材料有限公司 一种纳米材料改性的高抗氧化长水口及其制备工艺

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AU2211488A (en) * 1987-10-01 1989-04-06 Gte Laboratories Incorporated Oxidation resistant, high temperature thermal cyling resistant coatings on silicon-based substrates and process for the production thereof
JPH02183718A (ja) * 1989-01-09 1990-07-18 Mitsui Eng & Shipbuild Co Ltd グロープラグ
JPH0421582A (ja) * 1990-05-15 1992-01-24 Toshiba Corp セラミックス製品
US5264681A (en) * 1991-02-14 1993-11-23 Ngk Spark Plug Co., Ltd. Ceramic heater
US5249554A (en) * 1993-01-08 1993-10-05 Ford Motor Company Powertrain component with adherent film having a graded composition
US5668524A (en) * 1994-02-09 1997-09-16 Kyocera Corporation Ceramic resistor and electrostatic chuck having an aluminum nitride crystal phase
US5480695A (en) * 1994-08-10 1996-01-02 Tenhover; Michael A. Ceramic substrates and magnetic data storage components prepared therefrom
JPH1160356A (ja) * 1997-08-08 1999-03-02 Shin Etsu Chem Co Ltd 窒化アルミニウム複合基材及びこれを用いた窒化アルミニウム複合発熱体、窒化アルミニウム複合静電チャック、窒化アルミニウム複合ヒータ付静電チャック
TW477782B (en) * 1998-09-29 2002-03-01 Ngk Insulators Ltd Structural body and method of producing the same

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DE69937529D1 (de) 2007-12-27
US6387551B1 (en) 2002-05-14
KR20000023534A (ko) 2000-04-25
EP0990630A1 (en) 2000-04-05
TW477782B (en) 2002-03-01
DE69937529T2 (de) 2008-10-23
KR100381588B1 (ko) 2003-04-26
US20020041983A1 (en) 2002-04-11

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